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R. BAUMUNG INDUSTRIES LIMITED

DOCTOR CRUSHER

RECYCLABLE CONTAINER CRUSHER

OPERATING AND MAINTENANCE MANUAL

MODELS: #20 - #48 revision date Feb. 07, 2005.

PLEASE READ ALL INSTRUCTIONS CAREFULLY BEFORE INSTALLING AND OPERATING THIS MACHINE. DAMAGE OR INJURY MAY RESULT FROM IMPROPER USE OR INSTALLATION

DESCRIPTION:

The can and bottle crusher is a strong, simple RECYCLING TRUCK MOUNTED perforating and flattening machine. A rotor is hydraulically driven at low speed and high torque. The cans and bottles placed into the unit are force fed by a crammer into the mechanism and crushed between the rotor and a curved, traction lined, steel crush plate. The rotor is chain driven by a single hydraulic motor. The crammer is powered by a linkage bolted to the rotor sprocket. A flow control valve may be used to adjust speed and a spool valve may be used to turn the unit on and off. The crush plate is also spring loaded to handle material surges and provide relief in the event of an overload.

The entire unit has been built for the simplest possible servicing and maintenance. Wherever possible, standard 1/2-13 bolts are used. This allows most servicing to be done with a single wrench or impact socket. Every effort to leave adequate wrench and grease fitting clearance has also been made.

SAFETY:

WARNING: This machine is powerful enough to seriously injure anyone who comes in contact with moving parts. Therefore, take care when servicing and operating this machine.

MOVING PARTS CREATE A PINCH HAZARD. SHARP POINTS CREATE A PUNCTURE HAZARD. SHARP EDGES CREATE A CUTTING HAZARD.

The following instructions should always be

followed when operating or servicing the machine:

NEVER REACH INTO THE CRUSHER WHILE IT IS RUNNING.

NEVER OPERATE THE CRUSHER WITHOUT THE CHAIN COVERS.

AVOID LOOSE CLOTHING, LONG HAIR OR JEWELERY WHILE OPERATING.

DO NOT OPERATE THE CRUSHER WITHOUT A FEED HOPPER.

ISOLATE OR DISCONNECT THE HYDRAULIC LINES BEFORE SERVICING.

IN THE EVENT THAT THE CRUSHER HAS TO BE REMOVED FROM THE INSTALLATION, USE THE PROPER LIFTING TOOLS.

ENSURE THAT AN APPROVED EMERGENCY STOP VALVE AND PULL CORD OR OTHER STOPPING DEVICE IS PROPERLY INSTALLED PRIOR TO USE.

DO NOT OPERATE IN REVERSE FOR LONGER THAN 2 SECONDS WITH MATERIAL IN THE UNIT, SEVERE DAMAGE MAY RESULT.

DISCLAIMER:

If good sense is used when operating and maintaining the unit, safety should not be a concern. R. Baumung Industries Limited, its associates, partners, employees, agents and assigns accept no liability whatsoever for damage to users equipment, product, goods, materials, employees or the public arising from either the proper or improper use of this machine.

All liability for damage or injuries howsoever caused is the sole responsibility of the user of the machine.

ATTENTION! WARNING! ATTENTION!

A SPECIAL "FUSEBOLT" SYSTEM HAS BEEN INSTALLED TO PREVENT DAMAGE TO THE FRONT PLATE AND ANTIWRAP ASSEMBLY. THIS SYSTEM IS SPECIFICALLY DESIGNED TO RELEASE UNDER ABNORMAL PRESSURE CONDITIONS.

NEVER REPLACE A SPECIAL "FUSEBOLT" ASSEMBLY WITH ANY OTHER TYPE OF FASTENER. SEVERE DAMAGE MAY RESULT WHICH WILL VOID WARRANTY. USE A 2.25 INCH 1/2 -13 BOLT. USE A LOCK WASHER BETWEEN 2 FLAT WASHERS AND TIGHTEN SPECIAL NUT UNTIL LOCK WASHER FLATTENS. DO NOT OVERTIGHTEN.

FOR YOUR CONVENIENCE, TWO ( 2 ) EXTRA "FUSEBOLT" ASSEMBLIES HAVE BEEN INCLUDED WITH THIS UNIT STORED UNDER THE CHAIN COVER. ADDITIONAL "FUSEBOLT" ASSEMBLIES MAY BE OBTAINED BY CONTACTING THE MANUFACTURER.

OPERATION:

The crusher has been lubricated in the factory before delivery. It is recommended that your maintenance department also lubricate the unit before it is put into service to ensure adequate lubrication and comply with warranty terms. Before using this crusher all operators must be made aware of the safety rules outlined on the previous page.

The crusher will flatten all household blue box recyclable containers made of glass, plastic or metal. Plastic containers and aerosol cans will also be punctured during crushing. Contact the manufacturer for details on the maximum/minimum size of containers which may be crushed and the throughput rating of each specific crusher model.

To crush containers, simply dump them into the hopper and activate the machine. Containers should not be inside one another or interlocking may occur. The operator may move to the next collection stop while the machine automatically processes the material and discharges it into the collection vehicle compartment.

Avoid throwing non crushable material or containers into the hopper which exceed the maximum size rating of the unit as blockage may occur. The geometry of the crusher is not designed to handle oversize containers or solid, uncrushable objects (e.g. frying pans, car parts or large stones) and they may not be processed through the machine resulting in blockages between the rotor and crush plate. An optional hydraulic reversing valve is recommended for applications where blockages are frequent due to oversize or uncrushable material. A reversing valve will aid operators in clearing most blockages that may occur. Should a reversing valve be installed, the following warning should be posted on the unit and must be followed or damage will result.

 WARNING:

Lids need not be removed from containers. Spikes on the rotor will puncture the containers and expel any trapped air during crushing. Considerable pressure is placed directly on containers during processing. This may result in the pressurized discharge of any liquids remaining in the containers, especially aerosol containers. This will not damage the machine, however, operators are cautioned to wear safety glasses and avoid exposing bare skin in close proximity to discharge and feed hopper areas when the machine is processing. All glass placed in the machine will be broken into small pieces. Glass pieces are a cutting/puncture hazard and should be avoided by operators. Metal cans are occasionally crushed in such a way that sharp edges could be exposed creating a cutting hazard. Care should be exercised in handling any crushed material and cut resistant gloves are strongly recommended along with suitable protective clothing.

The unit is adjusted for optimum compaction at the factory and should not require adjustment prior to operation. Should the operator desire less compaction, remove the chain cover, unlock the spring tensioner adjustment nuts at the bottom of the unit and screw the adjusters open. Care should be taken not to set the spring tensioner too firmly or the unit may stall under heavy load.

WARNING:

The operating speed of the unit may be controlled with an hydraulic flow control valve. Maximum speed should not exceed 50 revolutions per minute. It is recommended that the unit be operated only as fast as required to keep up with production. Slower operation will extend the life of all components. Installation of a pressure relief valve is also strongly recommended.

With the exception of speed and plate tension, no other adjustments are necessary or required by the operator. Speed and plate tension are generally set once and are not changed until the next regularly scheduled service of the unit.

LUBRICATION:

All of the bearings and chains must be lubricated at least once a month. Under heavy use more frequent lubrication may be necessary.

NOTE: Warranty will be voided if the recommended lubrication schedule is not followed by the user.

Before commencing with lubrication make sure the unit power source is locked out. All of the components requiring lubrication will be accessible after removal of the chain cover. The bearings can be lubricated with the same grease used for vehicle lubrication. Vehicle grease is of sufficient quality for warranty purposes. Two or three shots in each grease nipple is adequate. Do not over grease bearings as seals will be damaged causing premature bearing failure.

The chain can be lubricated with crankcase oil. The oils used in diesel engines are of good quality and will be adequate for this purpose. The chain should have a permanent film of oil on it at all times during operation.

Puncturing spike assemblies should be filled with grease each time they are removed for service or replacement.

Grease points are indicated on the diagram below.

MAINTENANCE:

The basic maintenance of this machine is simple. All of the bearings and chain drives must be lubricated on a regular basis. During lubrication, check nuts and bolts to ensure that all are tight and installed. Check that all bearing and sprocket set screws are installed and tight. Check for excessive wear of the chain, sprockets and bearings. Check the condition of the crush plate tensioner spring and adjuster bolts. Check that a suitable gap exists between the crush plate and rotor. Check for damage to antiwrap fingers and puncturing spikes.

The puncturing spikes should be inspected at least every time the machine is lubricated. Missing, broken or blunted spikes should be replaced immediately. The condition of the spikes directly affects the feeding efficiency of the unit. Replacement spikes and holders are always available from the manufacturer. A supply of spare spikes, spike springs and spike holders should be kept on hand at all times as spikes become dull with normal use and may break with improper use. Spikes should not be sharpened after installation.

NOTE: Spikes are manufactured from special metals hardened to specific tolerances. Use of spikes from any other source except the manufacturer will void the warranty.

Check for dull, bent or broken spikes often and replace them as necessary.

NOTE: If glass is routinely crushed along with plastic and metal containers, the spikes will become blunt much more rapidly. Check spikes biweekly and replace as required if glass is run through the unit. The spike holders are simply press fit into the rotor and can be removed with a standard 5/8 inch, 11 thread national course nut. Loctight or paint should not be applied to the spike holders as the taper lock holding system is machined to close tolerance and later removal will be made difficult. Grease should fully fill the spike spring cavity before reassembly to ensure spikes will retain free movement. Spike assemblies are set by placing an inverted spike holder over the spike assembly in the rotor block and tapping with a hammer until the holder is seated in the taper leaving the extraction threads exposed. (see diagram below).

NOTE: MAKE SURE THE ROTOR BLOCKS ARE VERY CLEAN BEFORE INSTALLING SPIKE HOLDERS OR THEY WILL NOT SEAT PROPERLY.

Check the metal traction rails on the crush plate for excessive wear regularly and replace if necessary. If the metal traction rails are absent, the crusher will not feed properly. Replacement traction rails are available from the manufacturer.

NOTE: Use of traction rails from any other source except the manufacturer will void warranty.

Inspect the spring on the crush plate tensioner periodically. Adjustment should not normally be required. Replace springs if they are damaged, deformed or missing. Springs are specifically matched in size and strength to each crusher model and are available from the manufacturer.

NOTE: Use of springs from any other source except the manufacturer will void warranty.

The machine is strongly built, however, care should be taken not to drop the unit or apply excessive mechanical force to it during servicing, lifting, removal or installation.

NOTE: Mechanical abuse of any kind, as determined solely by the manufacturer, will void warranty and may result in difficulty servicing the machine as well as injury to operators.

Do not over tighten fasteners. Over tightening may result in breakage or misalignment of bearing housings and other machine components. Over tightening may result in stripped threads on fasteners which will weaken the structural integrity of the unit. Do not operate the unit unless all fasteners are securely in place, as DAMAGE OR INJURY MAY RESULT. All fasteners have been specifically selected for size and strength. Any stripped fasteners should be immediately replaced with new fasteners supplied by the manufacturer. Use of fasteners from any other source except the manufacturer will void the warranty and may cause injury.

The surface of the machine may be cleaned with pressure washers, or with soap and water. Periodically remove any material that is trapped on the antiwrap fingers and rotor. Monthly remove the crammer cover plate and inspect the area behind the crammer and crush plate. Remove any foreign material and reinstall the crammer cover plate. Do not operate the machine without the crammer cover plate.

Do not operate the machine in reverse for longer than two (2) seconds which is adequate to back out any blockage into the feed throat area for removal. The machine may be reversed for periods exceeding two seconds ONLY if the hopper is empty. NOTE: Operating the machine in reverse with a full hopper will cause serious damage to the components. Operating the machine in reverse for extended periods will void the warranty and may cause injury. A special protection system for the front plate assembly has been bulit into all models newer than 1998. This "fusebolt" system will release an overstressed front plate and antiwrap assembly and reduce damage to the unit.

NOTE: replace blown fusebolt components with manufacturer supplied parts only. Failure to use authorized replacement fusebolt parts will result in failure of the protection system and void the warranty.

NEVER use regular bolts in place of fusebolt assemblies. Two spare fusebolt assemblies are provided under the chain cover. Do not over tighten special fusebolt nuts.

SPARE PARTS:

All maintenance and service specifications should be followed according to the manufacturer's instructions. All units are built to close tolerances and strict quality standards.

NOTE: Use of parts not supplied or authorized in advance by the manufacturer may void the warranty, damage the machine or injure operators. Replace all damaged, worn or loose parts immediately. Spare parts are available from the manufacturer on short notice. Hydraulic components are also available through the manufacturer. Technical advice and special purpose machines are also available through the manufacturer.

WARRANTY:

Provided crusher units are used for the purpose supplied, each unit is warranted to be free from defects in parts and labour for a period of one year from the date of purchase. Each machine is stamped with a manufacturers serial number located under the chain cover on the top right of the drive side plate. No parts will be supplied under any circumstances without a valid serial number. Worn or damaged parts must be returned to the manufacturer for repair or replacement at the manufacturer's option. Warranty excludes any shipping and duty costs.

Parts damaged through neglect or abuse, as determined solely by the manufacturer, are not covered under warranty.

FOR ADDITIONAL INFORMATION, OR SPARE PARTS,

PLEASE CONTACT:

R. Baumung Industries Ltd.
844674 Braemar Rd.
R.R. 2 Tavistock
ONTARIO. CANADA, N0B 2R0
TEL. 1-519-462-2500
FAX. 1-519-462-2500

Email: DrCursher@Egroup1.com

TECHNICAL SUPPORT:

Technical support is available from the manufacturer or contact your nearest distributor.

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